Vehicle front end including a vehicle front end element and method for manufacturing an air duct arrangement

Abstract

The invention relates to a vehicle front end comprising a vehicle front end element and a method for manufacturing an air duct arrangement, in particular to a vehicle front end having at least one vehicle front end element with an opening leading to an air duct arrangement positioned downstream of the at least one opening, and to a method for manufacturing an air duct arrangement for such a vehicle front end element. The object of the invention is to provide a vehicle front end element having an opening leading to an air duct arrangement and a method for producing an air duct arrangement for a vehicle front end element which results in low production costs and still keeps assembly costs low. The vehicle front end element according to the invention comprises at least one opening leading to an air duct arrangement positioned downstream of the opening, wherein the air duct arrangement provides a surrounding channel, and wherein the air duct arrangement is formed by at least two segments connected by an integral hinge.

Description

Technical Field

[0001] The invention relates to a vehicle front end comprising a vehicle front end element having an opening leading to an air duct device positioned downstream of the opening, and to a method for manufacturing an air duct device for a vehicle front end, in particular for a vehicle front end element having an opening as mentioned above. The invention relates in particular to a vehicle front end for a motor vehicle, such as a car or a truck, in particular with a combustion or engine, with an electric engine and / or with other drive trains including hybrid drive trains. Explicit reference is made to a motor vehicle comprising a front bumper cover as a vehicle front end element, the front bumper cover comprising at least one opening, preferably two openings or more openings, the opening(s) directing air through the air duct device to the front wheel housing. Such an air duct device is also referred to as an air curtain. Background Art

[0002] DE 10 2010 037 616 A1 discloses an air guiding element arrangement for a motor vehicle, which is attached to the underbody in front of the front wheels of the motor vehicle. The air guiding element arrangement comprises at least one air guiding element which is arranged vertically with respect to the road surface and arranged at an angle to guide air around the wheel. A movable embodiment of the air guiding element is also mentioned, which is attached to the underbody by a joint or an integral hinge, thereby allowing the air guiding element to change angle depending on the wind pressure. Summary of the invention

[0003] The object of the invention is to provide a vehicle front end comprising a vehicle front end element having an opening to an air duct arrangement and a method of producing an air duct arrangement for a vehicle front end which results in low production costs and keeps assembly costs low.

[0004] The vehicle front end according to the invention comprises at least one vehicle front end element having at least one opening leading to an air duct device positioned downstream of said opening, wherein the air duct device provides a surround passage, and wherein the air duct device is formed by at least two segments connected by an integral hinge. Preferably, the integral hinge is oriented parallel to one of the main directions of the air duct device, such as the length, width or height of the air duct device. If the air duct device has a cuboid form, such directions are preferably understood based on the air flow direction, for example, the length will be understood to be parallel to the air flow direction, the width will be understood to be transverse to the air flow direction, in particular, orthogonal to the air flow direction, and the height will be understood to be orthogonal to the width and length.

[0005] Surrounding the channel means that the channel extends (considered to be in the circumferential direction) to the entire periphery at least at a certain longitudinal section of the air duct device. In this regard, the periphery is not limited to the periphery of a circle, but relates to all kinds of cross-sectional shapes, in particular to prismatic cross-sectional shapes, such as rectangular cross-sectional shapes or other square or polygonal cross-sectional shapes.

[0006] The air duct device of the front end of the vehicle according to the present invention has the following advantages: the integral hinge can be used to form the air duct device from a single piece with two (or more) segments, wherein the segments are brought to each other in one position, thereby forming an air duct device with a surrounding channel. In particular, if the device is a molded part and thus requires a mold, the fact that the air duct device can be produced in a single piece keeps the production costs low. In addition, the assembly of the air duct device is simple, because it is sufficient for the air duct device to make the segments rotate around the integral hinge and fix the elements when forming the channel. The integral hinge ensures the appropriate relative position between the two segments when the segments are in contact with each other so as to form the channel. Thus, it is not necessary to coordinate the availability and / or movement of two or more separate parts. In addition, the air duct device is sufficient to connect the segments only at a single connecting section (in particular, the connecting line).

[0007] The air duct device may in particular be attached to a vehicle front end element having an opening as mentioned above. Alternatively or additionally, the air duct device may be connected to any other vehicle front end element, in particular to those front end elements located adjacent to the air duct device, and / or directly or indirectly to a vehicle front end element having the mentioned opening.

[0008] In a preferred embodiment of the invention, the air duct arrangement of the vehicle front end is made of a plastic material. In particular, the air duct arrangement is made in one piece, for example, as an injection-molded part. Thermoplastic materials and thermosetting materials are mentioned in particular.

[0009] In a further preferred embodiment, the wall thickness of the air duct arrangement at the front end of a vehicle according to the invention, at least in a main section surrounding the channel, is in the range of 1.5 mm to 4 mm, particularly preferably 2.0 mm to 3.0 mm.

[0010] Alternatively or additionally, the wall thickness of the integral hinge is in the range of 0.6 mm to 1.5 mm, preferably in the range of 0.7 mm to 1.2 mm, and most preferably in the range of 0.8 mm to 1.0 mm.

[0011] Particularly if the air duct device is manufactured from a plastic material, the wall thickness as mentioned above provides options for efficient manufacturing in combination with a durable and high quality product.

[0012] The invention has additional manufacturing and assembly advantages if the air duct device comprises at least one connecting structure allowing the at least two segments to be fixed in the passage position. In this case, the air duct device itself provides means for fixing the at least two segments after they have been brought into the passage position.

[0013] Preferably, at least one connecting structure comprises one or more clamp elements with one or more corresponding clamp receiving parts. Such clamp elements and clamp receiving parts may be part of a one-piece air duct device, in particular, a one-piece air duct device made as an injection molded part and / or made of plastic material.

[0014] In a further preferred embodiment, at least one air duct arrangement of a vehicle front end according to the invention extends primarily from an air opening to a rear position in a vehicle front end element, thereby allowing air to flow longitudinally through the vehicle front end element, the air opening being positioned at a front position in the vehicle front end element and being oriented forwardly with respect to the driving direction of the vehicle. In this case, the vehicle front end element may comprise only: a front design with at least one (air) opening, such as a main body shell part with a front bumper cover having an opening; and a longitudinal extent, i.e. an extent in the longitudinal direction of the vehicle. The air duct arrangement, which is suitably attached so that the channel front opening is positioned downstream of the at least one opening, provides a passage for air to flow from the at least one opening through the channel to an outlet opening of the channel located at a rear position in the vehicle front end element.

[0015] In a context as mentioned above, predominantly means that the channel at least extends over at least 50%, preferably over 70% or 80% and most preferably over more than 90% or 100% of the longitudinal extent of the vehicle front end element.

[0016] The invention is made in particular for a vehicle front end element, wherein at least one opening is part of a front bumper cover or an air inlet grille (also a radiator grille), and wherein an air duct arrangement leads to the front wheel housing, in particular to a front position of the front wheel housing. As mentioned above, such an air duct arrangement is also referred to as an air curtain. Preferably, such a vehicle front end element comprises two openings, wherein each opening leads to a channel which leads to the front wheel housing. Two or more openings in combination with one or several vehicle air duct arrangements are also mentioned.

[0017] The vehicle front end according to the invention may have further advantages in case the air duct arrangement comprises a front bearing surface and / or a rear bearing surface which are oriented transversely to the direction of the air flow through the channel. In this case the assembly may be arranged by bringing the air duct arrangement into a position relative to the vehicle front end element in which the front bearing surface abuts against the front bearing surface and / or the rear bearing surface abuts against a rear part of the vehicle front end element.

[0018] The present invention also relates to a method for manufacturing an air duct device for a front end of a vehicle, in particular to a method for manufacturing an air duct device for a front end element of a vehicle as described above or hereinafter, the air duct device having two segments connected by an integral hinge, wherein the air duct device is produced in an elongated position of the air duct device in a first process step, and wherein, in a second process step, the two segments are rotated around the integral hinge in a manner to form a surrounding passage. The elongated position means that the integral hinge is used to bring the air duct device to a position in which the maximum length and / or maximum width are reached. In the elongated position, the production process requires a minimum cost for preparing and using a mold, particularly in the case of producing the air duct device by injection molding. Thus, the method as outlined above allows the cheap production of the air duct device as described above as a single-piece element. In addition, the integrated hinge allows improved assembly, particularly the predetermined relative position of the two segments when brought to the passage position as described above.

[0019] In a further preferred method of the invention, the air duct device is made of a plastic material and / or the air duct device comprises at least one connecting structure, wherein the connecting structure is used in or after the second process step to fix the at least two segments in the channel position. The advantages mentioned above with respect to plastic materials are mentioned. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Further useful embodiments of the present invention are described below in conjunction with the accompanying drawings.

[0021] The attached figure shows:

[0022] Figure 1 is a cutaway portion of a vehicle front end with a front end part according to the invention realizing a front bumper cover, in a perspective front view,

[0023] Figure 2 It is a perspective rear view. Figure 1 The cutaway portion marked with II in FIG. 1 , wherein the air duct device is in an elongated position,

[0024] Figure 3 It is a perspective rear view. Figure 1 The cut-away portion marked with II in the figure, wherein the air duct device is located in the channel position,

[0025] Figure 4 It is from the back. Figure 2 an enlarged view of further details of the air duct arrangement shown in FIG.

[0026] Figure 5 It is free Figure 2 The front side shown in Figure 2 An enlarged view of further details of the air duct arrangement shown in FIG. DETAILED DESCRIPTION

[0027] In the drawings and hereinafter, the X direction (reference arrow X) means the longitudinal direction of the vehicle, the Y direction (reference arrow Y) means the lateral direction of the vehicle, and the Z direction (reference arrow Z) means the vertical direction (not shown) of the vehicle.

[0028] Figure 1 A cutaway portion is shown from the left side (in the view of the vehicle driver) of the front end 50 of the vehicle having the front bumper cover 12 and the radiator grille 14. The front bumper cover 12 includes a plurality of openings such as Figures 2 to 5 The opening 16 of the air duct arrangement 18 is shown.

[0029] On the right side of the vehicle front end 50 , the front bumper cover 12 comprises another symmetrical opening (not shown) which also leads to an air duct arrangement (not shown).

[0030] In the following, only the left side of the vehicle front end 50 and the corresponding opening 16 are mentioned, which allows air to flow as in Figure 3 1 and 12. The air flows through the front bumper cover 12 as shown by air flow arrows 20, wherein the air is directed through a passage 22 formed by the air duct arrangement 18. Downstream of the opening 16, the air directly enters the air duct arrangement 18. The passage 22 of the air duct arrangement 18 leads to a rear opening 48 located at a rearward position of the front bumper cover 12. The air that exits the passage 22 and flows through the rear opening 48 as shown by the air flow arrows 20 flows into a front wheel housing (not shown) of a vehicle (not shown).

[0031] like Figure 2 , Figure 4 as well as Figure 5As shown in FIG. 1 , an exemplary air duct device 18 according to the present invention is manufactured as a one-piece part (i.e., an injection molded part). The air duct device 18 is preferably made of a plastic material. The air duct device 18 includes a first segment 24 and a second segment 26, which are connected by an integral hinge 28. The integral hinge 28 is formed as a hinge that provides a hinge axis (a) and allows relative movement of the mentioned segments 24, 26 about the hinge axis (a). In an exemplary embodiment, the integral hinge 28 is oriented parallel to the length of the air duct device 18 and parallel to the air flow direction.

[0032] In the example as shown, the wall thickness of the segments 24, 26 is in the range of 2.0 to 3.0 mm, in particular 2.5 mm. The wall thickness of the integral hinge 28 is in the range of 0.8 to 1.0 mm, in particular 0.9 mm.

[0033] Although Figure 2 , Figure 4 as well as Figure 5 The air duct device 18 is shown in an elongated position when the air duct device 18 is manufactured by injection molding, but Figure 3 The air duct arrangement 18 is shown in an assembled position. The assembled position may be created prior to attaching the air duct arrangement 18 to the vehicle front end element 10, in this case the front bumper cover 12 (not shown). Alternatively, the assembled position may be created prior to attaching the air duct arrangement 18 to the vehicle front end element 10, in this case the front bumper cover 12 (not shown). Figure 2 The connection to the front bumper cover 12 is produced as shown in FIG.

[0034] To produce the assembled position of the air duct device 18, it is required to move the segments 24, 26 relative to each other by pivoting said segments 24, 26 about the hinge axis (a).

[0035] like Figure 4 and Figure 5 As shown in FIG. 1 , the air duct device 18 includes a connection structure 30 in the form of a clamp element 32 and a clamp receiving portion 34. The connection structure 30 is positioned in a manner that allows the following: Figure 3 After the segments 24, 26 are placed in the assembly position as shown in FIG, each clamp element 32 is mechanically connected to the corresponding clamp receiving portion 34, thereby Figure 3 The segments 24, 26 are fixed in the passage position as shown in FIG.

[0036] In the embodiment as shown in the drawings, each segment 24 , 26 has an L-shaped cross-section with a vertically extending main wall 36 , 38 and a transverse wall 40 , 42 extending transversely.

[0037] Furthermore, the segments 24 , 26 comprise a front bearing surface 44 and a rear bearing surface 46 , said bearing surfaces 44 extending in a direction transverse to the main walls 36 , 38 and transverse to the transverse walls 40 , 42 .

[0038] In the assembled position, as Figure 3 As shown in FIG. 1 , the air duct arrangement 18 extends in a longitudinal direction and in a transverse direction.

[0039] The features of the invention disclosed in this description and in the drawings may be essential not only individually but also in any combination for implementing the invention in its various embodiments. The invention is not limited to the embodiments described. The embodiments can vary within the scope of the invention and taking into account the knowledge of competent experts.

[0040] Reference Number

[0041] 10Vehicle front end components

[0042] 12Front buffer cover

[0043] 14 Radiator grille / air inlet grille

[0044] 16 Opening

[0045] 18 Air duct device

[0046] 20 air flow arrows

[0047] 22 channels

[0048] 24(First) Segment

[0049] 26(Second) Segment

[0050] 28 integrated hinge

[0051] 30 Connection structure

[0052] 32 fixture elements

[0053] 34 clamp receiving part

[0054] 36 Main Wall

[0055] 38 Main Wall

[0056] 40 Horizontal wall

[0057] 42 lateral wall

[0058] 44Front bearing surface

[0059] 46 Rear bearing surface

[0060] 48 rear opening

[0061] 50Vehicle front end

[0062] aHinge axis

Claims

1. A vehicle front end comprising at least one vehicle front end element (10) having at least one opening (16) and an air duct arrangement (18) positioned downstream of the at least one opening (16), wherein: The at least one opening (16) leads to the air duct device (18), wherein the air duct device (18) provides a surrounding passage (22), and wherein the air duct device (18) is formed by at least two segments (24, 26) connected by an integral hinge (28), wherein the surrounding passage (22) is formed by pivoting the two segments (24, 26) about the integral hinge (28), wherein the air duct device (18) comprises a front bearing surface (44) and a rear bearing surface (46), and wherein the front bearing surface (44) abuts against a front bearing surface of the vehicle front end element (10) and the rear bearing surface (46) abuts against a rear portion of the vehicle front end element (10).

2. The vehicle front end according to claim 1, characterized in that The air duct device (18) is made of plastic material.

3. Vehicle front end according to one of the preceding claims 1 to 2, characterized in that The wall thickness of the air duct device (18) at least in a main section of the surrounding channel (22) is in the range of 1.5 mm to 4.0 mm, and / or the wall thickness of the integral hinge (28) is in the range of 0.6 mm to 1.5 mm.

4. Vehicle front end according to one of the preceding claims 1 to 2, characterized in that The air duct device (18) comprises at least one connecting structure (30) allowing the at least two segments (24, 26) to be fixed in a passage position.

5. The vehicle front end according to claim 4, characterized in that The at least one connecting structure (30) includes one or more clamp elements (32) having one or more corresponding clamp receivers (34).

6. Vehicle front end according to one of the preceding claims 1 to 2, characterized in that At least one air duct arrangement (18) extends primarily from an air opening (16) to a rear position in the vehicle front end element (10), thereby allowing air to flow longitudinally through the vehicle front end element (10), the air opening (16) being located at a front position in the vehicle front end element (10) and oriented forwardly with respect to the driving direction of the vehicle.

7. Vehicle front end according to one of the preceding claims 1 to 2, characterized in that The at least one opening (16) is part of the front bumper cover (12) or the air inlet grille (14), and the air duct arrangement (18) leads to the front wheel housing.

8. Vehicle front end according to one of the preceding claims 1 to 2, characterized in that The front bearing surface (44) and / or the rear bearing surface (46) are oriented transversely to the direction of air flow through the surrounding passage (22).

9. A method of manufacturing a vehicle front end (50) comprising at least one vehicle front end element (10) having at least one opening (16) and an air duct arrangement (18) positioned downstream of the at least one opening (16), wherein: The air duct device (18) has at least two segments (24, 26) connected by an integral hinge (28), wherein the air duct device (18) is produced in a first process step in an elongated position of the air duct device (18), and wherein, in a second process step, the two segments (24, 26) are pivoted around the integral hinge (28) in such a way as to form a surrounding channel (22), wherein the air duct device (18) comprises a front bearing surface (44) and a rear bearing surface (46), and wherein the air duct device (18) and the vehicle front end element (10) are brought into a relative position in which the front bearing surface (44) abuts against the front bearing surface of the vehicle front end element (10) and the rear bearing surface (46) abuts against the rear part of the vehicle front end element (10).

10. The method according to claim 9, characterized in that The air duct device (18) is made of plastic material and / or the air duct device (18) comprises at least one connecting structure (30), wherein the connecting structure (30) is used during or after the second process step to fix the at least two segments (24, 26) in the channel position.

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